2000 BMW 540i warning

Downloaded from www.Manualslib.com manuals search engine
Steering and Wheel Alignment
Pitman arm, adjusting
As the vehicle suspension settles down, the toe on the left
and right wheels must remain identical for proper handling.
By adjusting the height of the
pitman arm, the left and right tie
rods are moved to the same ride level setting. This will opti-
mize straight-ahead travel on uneven road surfaces.
- Raise front of car. Remove splash shield from under engine.
WARNING-
Male sure the car is iirmly supported on jack stands de-
signed ior the purpose. Place jack stands beneath structural
chassis points. Do not place
jaclc stands under suspension
parts.
- Remove bolts from left and right inner control arm mounts.
Place
BMW special tool 32 2 140 through right side control
arm mounting bolt hole.
Loosen fastener
A and push pin El up so that it is firmly
against tie rod
(arrow). Tighten fastener A.
- Remove tool without disturbing position of pin El.
- Loosen pitman arm clamping bolt and slide arm up.
4 Place special tool 32 2 140 through left side control arm
mounting bolt hole.
Slide
pitman arm up or down until tie rod makes contact
with pin
(El).
Tighten pitman arm clamping bolt.
Tie rod height differences
Deviation between
left and right tie rod height -?-I .5 rnrn (LO6 in)

Downloaded from www.Manualslib.com manuals search engine
I Steering and Wheel Alignment
I I 4 Gap A = 0.5 - 8.5 mm (0.02 - 0.33 in)
- Reinstall inner control arm bolts
Tightening torques
Control arm to
subframe 78 Nm (58 it-lb)
(tighten with wheel on ground)
Pitman arm pinch bolt (note direction of threads) 61 Nm (45 ft-lb)
Steering idler arm, removing and installing
The idler arm is bolted to the subframe through a bushing.
The bushing is subject to wear and is available as a replace-
ment part.
- Raise front of car. Remove splash shield from under engine.
WARNING -
Male sure the car is firmly supported on jaclc stands de-
signed for the purpose. Place jack stands beneath structural
chassis points. Do not place jack stands under suspension
parts.
4 Remove center tie rod fastener and press tie rod out of idler
arm with
BMW special tool 32 1 190.
- Remove idler arm mounting bolt through opening in sub-
frame and remove idler arm from car.
- Installation is reverse of removal.
Make sure all thread bores, bolts, nuts and mating surfac-
es are clean.
Use new self
loclting nuts to mount idler arm to subframe
and center tie rod to idler arm.
If idler arm or idler arm bushing is replaced, adjust
pitman
arm as described earlier.
Have car professionally aligned.
Tightening torques
Center tie rod to idler arm 65 Nm (48 ft-ib)
(replace self-locking nut)
Idler arm to front subirame
(replace self-locking nut) 62
Nm (46 it-lb)

Downloaded from www.Manualslib.com manuals search engine
320-32
Steering and Wheel Alignment
Center tie
rod, replacing
- Raise front of car. Remove splash shield from under engine.
WARNING-
Make sure tlie car is firmly supported on jack stands de-
signed for the purpose. Place jack stands beneath structural
cliassis points. Do not place jack stands under suspension
parts.
- Measure length of left and right (outer) tie rods. Write down
measurements.
NOTE-
Accurate measurement of the tie rod end with reference to
the center tie rod will help approximate correct wheel align-
ment when new parts are installed.
4 Remove self-loclting nuts connecting center tie rod to pitman
and idler arms. Press tie rod off pitman and idler arms using
BMW special tool
32 1 190 or equivalent.
4 Loosen left tie rod clamping bolt (arrow). Unscrew left tie rod
from center tie rod. Repeat for right.
- Installation is reverse of removal.
Malte sure all threaded parts are clean.
. Coat threads with antiseize compound.
Replace self-loclting nuts.
Check tie rod end ball joints and idler arm bushing for wear.
Use tie rod measurements previously made to temporarily
set toe.
- Have car professionally aligned.
Tightening torques
Center tie rod to
pitman and idler arms 65 Nm (48 ft-lb)
(replace self-locking nuts)
Left or right outer
tie rod clamping bolt 27 Nm (20 it-lb)

Downloaded from www.Manualslib.com manuals search engine
330-5
Rear Suspension
REAR STRUTS AND SPRINGS
(SEDAN MODELS)
Rear strut assembly, removing and
installing
Replace struts and coil springs in pairs only.
- Raise car and remove rear wheels.
WARNING -
Male sure the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands underneath struc-
tural chassis points. Do not place jack stands under
suspension parts.
- Remove rear parcel shelf:
Remove rear seat headrests by pulling straight up.
Remove both rear roof pillar (C-pillar) trim panels.
Unbolt rear seat
belt anchors. See 720 Seat Belts.
Models with fixed rear seat: Remove rear seat backrest.
See 520 Seats.
* Models with fold-down rear seat: Remove rear seat back-
rest side sections. See 520 Seats. Fold down backrest.
* Working inside trunk, remove roller blind mounting nuts
and bolts, if applicable. Also disconnect roller blind har-
ness connector at right edge of rear seat backrest.
Gently pry rear speaker cover grilles and rear window defog-
ger grilles
(A) out of parcel shelf.
Carefully remove seat belt and headrest mount finisher
strips (B).
Remove
middle seat headrest anchor bolts (C). Remove
headrest anchor.
Remove expansion rivets (arrows) and lift out parcel shelf.
- Remove rear speakers.
- Remove rear wheels. Remove wheel arch trim
- Support rear wheel bearing carrier.
CAUTION-
The strutassembly prevents the drive axle and wheel bearing
carrier
from dropping too far. Supporting the wheel bearing
carrierbefore disconnecting the strut mounting fasteners pre-
vents damage to the brake hose, parking brake cable and
drive axle
CV joints.

Downloaded from www.Manualslib.com manuals search engine
Rear ~us~ensionl
Rear strut assembly, disassembling and
assembling
Replace struts and coil springs in pairs only
Replacing the upper strut mount, spring or strut requires that
the strut assembly first be removed from the car, as described
earlier. Strut disassembly requires a spring compressor.
WARNING-
Do not attempt to disassemble the strut without a spring com-
pressor designed specifically for the job.
- Remove strut assembly from car as described in Rear strut
assembly, removing
bnd installing
4 Mount spring compressor (BMW special tools 31 3 340 and
31 3 350 or equivalent) in shop vice. Install correct-sized
spring retainers
(A).
WARNING-
Do not attempt to disassemble the struts without a spring
compressor designed specifically for this job.
* Prior to using the spring compressor checlc its opera-
tion. Do not use a spring compressor that is damaged.
Do not make any modifications to the spring compres-
sor.
Never use an impact wrench to compress or relieve
tension when using a spring compressor.
1
- Place strut assembly coil spring in spring retainers. Com-
press spring until force on upper strut mount is relieved.
Remove strut top mount self-locking nut with BMW special
tool
31 2 21 0 while counterholding strut shaft with a box end
wrench.
- Remove upper strut mount and related components. Sepa-
rate strut from spring.
NOTE-
Store the removed shock absorber upright Do not allow it to
lie horizontally or upside down for any length of time. If incor-
rect storage has occurred, place the
shoclc absorber upright
with the rod
fully extended for at least 24 hours.
- Replace strut, rubber bumper, upper strut mount or spring,
as needed.
NOTE- Relieve tension on spring compressor slowly and carefully.
Fit new spring in spring compressor so that one coil at
each end is outside spring retainer.

Downloaded from www.Manualslib.com manuals search engine
330-8
Rear Suspension
4 Compress spring and install it and related components to
shock absorber. Use new self-locking upper strut mounting
nut.
1. Upper strut mount self-locking nut
2. Washer
3. Poor road surface adapter
4. Upper spring seat
5. Upper strut mount
6. Upper rubber bumper seat
7. Rubber bumper
8. Coil spring
9. Dust boot
10. Lower spring seat
I I. Strut
WARNING-
Male sure the upperself-locking nut is fully tightened before
releasing the spring compressor.
Tightening torque
Upper strut mount to strut shaft
27 Nm (20 ft-lb)
(M14, replace self-locking nut)
4 Before releasing spring tension, position upper strut mount
so that one threaded stud is on a plane with flat end of strut
bushing at other end of strut.
- Release spring compressorslowly, positioning spring ends in
shoulders of spring seats.
- Reinstall strut assembly in vehicle, as described above in
Rear strut assembly, removing and installing.

Downloaded from www.Manualslib.com manuals search engine
--
C. -- -- - -- Rear ~us~ensionl
Depending on year and model applications, the Sport Wagon
rear suspension may be equipped with:
Conventional shock absorbers and coil springs
Electronic height control (EHC) system which incorporates
air springs
NOTE-
. Suspension and EHC troubleshooting is covered in 300
Suspension, Steering and Brakes-General.
EHC system repairs, other than air spring replacement,
are covered in Electronic height control
(EHC) compo-
nent replacement.
Replace shock absorbers and springs in pairs only.
Rear shock absorber, removing and
installing
- Raise car and remove rear wheels,
WARNING-
Male sure that the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands underneath struc-
tural chassis points. Do not place
jack stands under
suspension parts.
CAUTION-
If working on a vehicle with compressedairshock absorbers,
disable air supply pump by disconnecting electrical plug be-
fore performing any repairs. Pump is located beneath a cover
under the spare tire in the floor of the cargo compartment.
- Support swing arm from below
CAUTIOG
The shock absorber prevents the drive axle and wlieel bear-
ing carrier from dropping too far. Supporting the wheel bear-
ing carrier before disconnecting the shock absorber
mounting fasteners prevents damage to the
brake hose,
parking
brake cable and drive axle CVjoints.
- Working in cargo compartment, remove carpet. Remove tri-
angular upper shock mount covers located beside spare tire
well.
- If applicable: Detach air supply line from shock absorber.
Plug ports and lines to keep out dirt.

Downloaded from www.Manualslib.com manuals search engine
330-1 1
Rear Suspension
Coil spring, removing and installing
Raise car and remove rear wheels.
WARNING-
Make sure the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands underneath struc-
tural chassis points. Do not place jack stands under
suspension parts.
- Remove brake caliper and brake disc. Hang brake caliper
aside with stiff wire. Do not disconnect
bralte fluid hose. See
340 Brakes.
- Remove exhaust system. See 180 Exhaust System.
- Disconnect driveshafl from final drive. See 260 Driveshaft.
- Detach parking bralte cables from mounting bracltets on sub-
frame.
< Support final drive unit from below using transmission jack
and
BMW special tool 33 4 390 or equivalent.
Remove rear suspension
subframe mounting bolts (arrows).
Lower rear
subframe until coil springs can be removed.
When reinstalling springs, replace upper and lower spring
pads if necessary.
Slowly lift suspension
back into position, making sure coil
springs are correctly seated in upper and lower spring seats.
Install and tighten
subframe mounting bolts. Note that on
each bolt, rubber-coated detent plate (arrow) must be in-
stalled at rear in driving direction
- Remainder of installation is reverse of removal
Tightening torques Road wheel
to hub 12OilO Nm (89i-7 ft-lb)
Subframe to body 163 Nm (120 ft-lb)